PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE REVISION 1 ISSUE DATE: DECEMBER 1995 Track Materials Engineer Engineering Services Group| [ PUBLIC TRANSPORT CORPORATION ‘TECHNICAL SPECIFICATION No. TM20 | He Sere ae ean —“ SIGNALS, RAILWAY TRACK, EXPLOSIVE CONTENTS SCOPE .. 2. TECHNICAL REPRESENTATIVE .. , 3. REFERENCED DOCUMENTS 3.1 Austealian Standards ........ 3.2 Quality Assurance Documents . 4. DESCRIPTION AND MARKING ...... 5. AUTHORISATION 6. LABELLING . eee severe Page 2 lee 7. TESTING ... z 7.1 Tyne Testing... z 4 72 4 4 i 4 7.3 Batch Production Testing Page 4 8. TESTING AND FACILITIES ...... 5.0... 0see eo veves Page 5 5 9. QUALITY ASSURANCE ...... Page § 9.1 General . on {1 Page 5 9.2 Test Certificates ..... Ll Page 6 _ 10. WARRANTY ......... eee eee ++ Page 6 ) \ a 11. PACKAGING wee eee 6 12, DELIVERY .. ee 6 = sarmteruzo0et 1, December, 1995 . i2. 4. PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE. ‘SPECIFICATION SCOPE This specification covers the requirements for explosive signals (where the explosion is initiated by friction) to act as audible warning devices when attached to railway tracks and run over by an approaching trair ‘The service required is for the manufacture, inspection, testing, supply and delivery of explosive signals in accordance with this specification and associated documents. ‘A Quality Assurance system shall also be implemented for the service required TECHNICAL REPRESENTATIVE The Corporation's Technical Representative shall be the Track Materials Engineer Tel: (03) 9619-4436 or 9619-4434, who will be responsible for all technical matters including those for Quality Assurance. REFERENCED DOCUMENTS 3.1. Australian Standards Unless otherwise nominated, reference is made in this specification to the current editions of the following Australian Standards:- AS 1199-1988 ‘Sampling Procedures and Tables for Inspection by Attributes AS 1259 Acoustics - Sound Lever Meters := Part 1-1990 Non integrating Part 2-1990 Integrating - Averaging AS 1399-1990 Guide to AS 1199 ASINZS ISO 9001 Quality system model for quality assurance design, development, production, installation and servicing. 3.2 Quality Assurance Documents PTC Quality Assurance document SQA 9001.2. DESCRIPTION AND MARKING 4.1. The explosive signals supplied shall be constructed, marked and coloured in a manner similar to the explosive signals already tested and approved by the Corporation. (Refer to “Testing” Clause 7 pevsrscmmzonoer Revision 1, December, 1995 Page 1PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE _ DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE 4.2 Additionally, the explosive signals shall be designed to be positively attached (i.e. clipped) to th head of the rail with sufficient force so as to prevent slippage in all weather and track condition when being run over by a train and to prevent removal by birds. AUTHORISATION ive authorisation for the storage, transport and use of the explosive signal in Victoria from the Health and Safety Organisation, Chemicals Technology Unit. (Telephone (0: 9628-8476) ‘The Classification Code so authorised shall be 1.4S. Documentation relating to the authorisation and in particular the explosive signal description an packaging description shall be made available to the Corporation if requested. LABELLING 6.1 Each inner container for packaging the explosive signals shall be labelled as follows or with th following information: 6.1.1 “Danger, ... Signals, Railway Track, Explosive". 6.1.2 Actual number of explosive signals. 6.1.3 “UN No. 0193". 6.1.4 “Class 1.48", 6.1.5 “Not liable to explode in bulk”, 6.1.6 Contractor's name. 6.1.7 Month and year of manufacture. 6.1.8 Batch or Lot Number of the explosive signals. 6.1.9 “Ensure Box is empty before discarding" or other equivalent wording. 6.1.10 Any other wording as required by the Health and Safety Organisation, Victoria 6.2 Each uter container for packaging the inner containers of explosive signals shall be labelled & follows or with the following informati 6.2.1 "Danger, .... Signals, Railway Track, Explosive", 6.2.2 Actual number of inner containers packed into the outer container. 6.2.3 Wordi as per Clause 6.1.2, 6.1.3, 6.1.4, 6.1.5, 6.1.6, 6.1.7 and 6.1.10. porrecmza0er Revision 1, December, 1995 - PagePUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION ‘TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE TESTING 7 ‘Type Testing The explosive signals, if not of the type of design previously approved for use by the Corporation shall be subjected to the following tests:- + SAFETY (Refer to Clause 7.1.2) + RELIABILITY (Refer to Clause 7.1.3) + NOISE LEVEL (Refer to Clause 7.1.4) The contractor shall submit test certificates and results for these tests to the Corporation's Technical Representative prior to or at the time of tendering. 7.1.1 Number of Explosive Sianals for Type Testing Sufficient number of explosive signals, that would have been manufactured in a normal Production run, shall be type tested by the contractor to enable the contractor to establish an acceptable quality level (AQL) for each test. As such, large scale testing ‘over a number of production batches would normally be required to establish the validity of the AQL’s selected. Care should be taken by the contractor in establishing AQL's as they would become integral to batch production sampling, its cost effectiveness and the level of reliability offered to the user. The method of establishing AL's shall be stated in the Contractor's tender. 7.1.2 Safety Test No explosive signals when tested as follows shall explode. The signal shall be fixed, in the normal manner, to a section rail. A steel weight of 11.3, kg, having a hemispherical striking surface of 75mm radius of curvature, shall be dropped centrally on the signal from 100mm height. 7.1.3 Reliability Test Every signal when tested as follows shall explode. The signal shall be tested by the method of Clause 7.1.2 with the exception that the weight shall be dropped from a height of 400mm. 7.1.4 — Noise Level Test Every signal when tested as follows shall register a noise level of not less than 150 dB. Linear Peak Hold. The signal shall be tested by the reliability test method as in Clause 7.1.3 and the noise level measurements may be performed during the reliability test. The noise level test shall be performed in a free field environment and the detonating apparatus shall be located at a distance not less than: 50 metres from any acoustically reflecting surface. arsecra0wet Revision 1, December, 1995 Page 3PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE The microphone of the sound level meter shall be located 6 metres from the test signal at a distance of 1.2m to 1.5m above the ground, with the microphone pointed in the direction of the test signal. The velocity of the wind, if any, during this test shall not exceed 8 m/sec. 7.1.4.1 Measurement Equipment ‘The Sound Level Meter shall comply “Sound Level Meters” - type 2. the Australian Standard AS 1259, The Sound Level Meter shall be able to measure the noise level of the detonated test signal in terms of dB. Linear peak hold (re 2 x 10 exponent- 5 Pa) The Sound Level Meter shall be calibrated prior to and immediately after each test program with an appropriate acoustic calibrator or equivalent device. 7.2 Service Trials The explo: /e signals which comply with the requirements of Clause 7.1 will be subjected to he “Running” and “User Evaluation” tests by the Corporation as follows: 724 7.2.2 ‘Bunning Tests ‘The Corporation will carry out a series of running tests, at variety of trains, speeds and rail conditions. Typical condition: 's own cost, involving a clude: Trains - passenger and freight Speeds - low (below 20 kph), medium (60-90 kph), high (up to 130 kph) Rail + dry, wet, straight or curved track. All explosive signals shall explode. All explosive signals shall be clearly audible to the train crew involved and to personnel observing the tests alongside the track. Fragmentation, if any, should be minimal. User Evaluation Following satisfactory performance in the running test of Clause 7.2.1, explosive signals will be issued by the Corporation, at its own cost, to a cross-section of user groups for evaluation prior to the Corporation entering into the Contract. 7.3 Batch Production Testing 7.3.1 Definition of a “Batch: A “batch” is defined as a quantity of explosive signals produced under conditions which are considered to be uniform. The manner and quantity by which a manufacturing batch is defined shall be stated in the Contractor's tender. Revision 1, Decornber, 1995 Page -4PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE 7.3.2 Testing: The contractor shall carry out tests on samples of each production batch of explosive signals. The testing shall include the following, using individual statistical sampling plans as per 7.3.3; SAFETY TEST —_—_ (Refer Clause 7.1.2) RELIABILITY TEST (Refer Clause 7.1.3) 7.3.3 Sampling Plans The contractor shall utilise individual statistical sampling plans for the Safety and Reliability Tests to AS 1199 using AS 1399. The number of explosive signals to be sampled or tested (for Safety and Reliability) by the contractor, for the qualification of each batch will depend on the batch size. Given the batch size and the AQL (established by the contractor and approved by the Corporation at the type testing stage) the sample size shall be determined from AS. 1199, Table 1 and Table 2-A, for General inspection Level 1 eg. For a batch size of 11,000 explosive signals, the sample size is 125. For a batch size of 1,500 explosive signals, the sample size is 80. Alternative sampling plans may be offered by the Contractor provided it can be proven to the Corporation that the proposed sampling plan would produce an equivalent or a lesser Consumer Risk. TESTING AND FACILITIES All costs incurred by the Contractor in the provision of test certificates or provision of labour and appliances necessary for all testing and inspections at his works during the currency of this agreement shall be included in the tendered price. QUALITY ASSURANCE 9.1 General The Contractor shall comply with PTC Quality Assurance Requirements as detailed in document SQA 9001.2. The Contractor shall perform and maintain records of results for all inspection and testing operations which demonstrate that the explosive signals are manufactured in accordance with this specification. All documentation shall be certified by the Contractor's Quality Assurance Representative. The format of all inspection record forms, test data forms and Certificate of Compliance shall be submitted to the Corporations Track Materials Engineer for approval prior to being implemented. ‘The Corporation reserves the right to perform compliance audits of the Contractor's Quality ‘System and to witness all inspection and testing. At the discretion of the Corporation's quality assurance representative, deliveries of explosive signals may be tested to determine compliance with this specification. ‘Aamsrcomzoner Revision 1, December, 1995 Page 510. 12. - Aaseecruzoroet Revision 1, December, 1995 PUBLIC TRANSPORT CORPORATION INFRASTRUCTURE DIVISION TECHNICAL SPECIFICATION No. TM20 FOR MANUFACTURE AND SUPPLY OF SIGNALS, RAILWAY TRACK, EXPLOSIVE, 9.2 Test Certificates The following test certificates shall be provided to the Corporation's Track Materials Engineer with each delivery of explosive signals:- 9.2.1 Contractor's Cert ate of Compliance. 9.2.2 The results of all tests performed to establish compliance with this specification. 9.2.3 The results of any additional testing as nominated by the Corporation's quality assurance representative. WARRANTY The *Certi ‘of Compliance” will be accepted as an implied warranty that the explosive signals of good quality and have been produced and tested in accordance with the requirements of this specification. PACKAGING The packaging shall be authorised by the Health and Safety Organisation, Victoria, for the products 1,48 classification. DELIVERY 12.1. The explosive signals shall be delivered free into store to the Permanent Way Materials Depot, McLister Street, Spotswood. 12.2 Delivery shall be deemed to be provisional until the Corporation certifies that the whole of this service is in accordance with this specification and its associated documents and is in every respect satisfactory.